Machine Tool CH # 03

Testing of Machine Tools

Machine tools are subjected to various tests before they are sent for sales. Sine machine tool
consists of various parts assembled together such as motor shafts, couplings, gears, clutches, bearings,
coolant pumps and other structures such as columns, beds, gear boxes, tail stock, head stock etc.
Certain basics tests are essential for smooth operation of machine tool. Tests also deal with
temperature increase in certain parts such as bearings. The rise in temperature in bearings should be
within permissible limits. The entire structure of machine tool should be stiff and rigid. The bed of the
machine tool is normally made of cast iron to have more vibration proof characteristics. The amplitude
of vibrations should be within the desired range.
The accuracy and surface finish of the parts produced by a machine tool depends upon many
factors. One of these factors is the accuracy of machine tools. Therefore, to produce parts economically
and accurately it is essential that the machine tool on which the parts are produced is accurate. An
inaccurate machine tool cannot produce accurate parts. To check how accurate a machine tool is it very
important to test the machine tool to certain accepted standards.
Testing of a machine tool has the following advantages:
i) By testing of a machine tool it can be put in a proper grade or precision class, thereby
helping a purchaser to know what he can expect from the machine tool.
ii) Testing helps in preventive maintenance of a machine tool.
iii) Testing helps in determining the condition of the machine tool and hence its useful life.

There are two types of tests:

i) Geometrical tests or Alignment tests.
ii) Practical tests or Performance test.

i) Geometrical tests or Alignment tests.

Geometrical tests cover the manufactured accuracy of machine tools. They are checked
on the relationship of the various elements of the machine tool when it idle and
unloaded.
ii) Practical tests or Performance test.
Practical tests are used to check the working accuracy of a machine tool. Both these are
collectively known as Acceptance Tests.

Testing of machine tool may be carried out in the following cases:

i) Before a machine is dispatched from the manufacturer to the customer.
ii) After a new machine has been installed and leveled.
iii) When a machine has been overhauled.
iv) When a machine is not giving satisfactory performance.

The degree of working accuracy of a machine tool, besides depending on machine tool itself, is
also influenced by the following factors:
i) Type of cutting tool and its condition.
ii) Tool material.
iii) Cutting speed, feed and depth of cut.
iv) Material to be machined.
v) Clamping equipment.
vi) Skill of the operator.
Testing Equipment:
The various tools and equipments used for carrying out the acceptance tests are as follows:
i) Dial gauge: The dial gauge should have clearly readable gradations on sufficiently
large dial. It need be finer than 0.001mm.
ii) Spirit level: Both horizontal and frame type spirit levels are used. It should have a
sensitivity varying from 0.03 to 0.05mm per meter for each division.
iii) Straight edge and squares: They are used to check straightness or flatness. They are
made up of cast iron or steel. They should have a strong ribbed construction with
wide bearing surfaces.

1/2 08MR-20
 Machine Tool CH # 03

iv) Test mandrels: They are used to check the true running of the spindle of the
machine tools. They are accurately turned hardened and ground. A test mandrel is
so chosen in length and diameter that the deflection due to its weight is negligible.
v)
The test mandrels may have either a taper shank for being fitted in the nose of the
machine spindle or a round shank for being held between the centers.

Maintenance of Machine Tools:

Maintenance can be defined under three main headings as follows:
i) Preventive maintenance.
ii) Corrective maintenance.
iii) Reconditioning.

1.Preventive Maintenance
The aim of preventive maintenance is to reduce wear and tear and to prevent to disruption to
production. Lubrication is generally considered to be heat of preventive maintenance of machine
tools. All moving parts are subjected to sliding or the rolling friction and in both the cases the
lubrication is must. Depending upon the lubrication methods used in the machine tool, lubrication
schedules are formed.
In machine tools there are three certain points which if not checked periodically not only
reduce the efficiency of the machine but tool also may lead to major break-down. Therefore,
regular inspection of such points is quite essential. All wearing parts in the machine tool or the
parts subjected to fatigue are replaced normally before failing in a prevention maintenance system.
Preventive maintenance is the planned maintenance of machine tools and equipment. A regular
planned preventive maintenance consists of a minor and medium repairs and major overhauls.
Preventive maintenance plays an important role in achieving reliability in the use of the system.
The preventive maintenance program can account for the most efficient operation of machines
which can result in high productivity.
Preventive maintenance is essential to keep the machine in order for production and safety.
A proper preventive maintenance schedule should be followed such as under:
A. Daily Checks
The following duties should be performed by the operator:
i) To clean the machine.
ii) To check lubricating oil levels and oil flow in sight glasses.
iii) To checks coolant level.
iv) To keep the maintenance department informed of even the minor defects noted
in the performance of the machine.
B. Weekly Checks
The following checks should be carried out by the maintenance department:
i) To check all lubrication levels
ii) To check coolant.
iii) To check all filters
iv) To check hydraulic and pneumatic lines
C. Monthly Checks
(To be carried out by the maintenance department)
i) To check spindle drive belts for wear
ii) To check hydraulic pumps and hydraulic oil
iii) To check movement of all axis under manual dial in control
D. Six Monthly Checks
i) To checks machine alignment
ii) To replace oil and filters
2.Corrective maintenance
3.Reconditioning

2/2 08MR-20